Controller and motor assembly comprising same

ABSTRACT

A controller including a first housing; a first cover disposed on an opening of the first housing; filter units disposed above the first cover; a power module unit disposed below the first cover; and a substrate disposed below the power module unit; wherein the power module unit includes a bracket; and a power module disposed between the bracket and the first cover, and wherein the power module includes a power module body; a plurality of first pins arranged to protrude downward from one side of the power module body; and five terminal pins arranged to protrude downward from the other side of the power module body, wherein an end portion of the first pin is coupled to the substrate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. Application No. 16/647,813filed on Mar. 16, 2020, which is the National Phase of PCT InternationalApplication No. PCT/KR2018/008514, filed on Jul. 27, 2018, which claimspriority under 35 U.S.C. § 119(a) to Pat. Application Nos.10-2017-0128155, filed in the Republic of Korea on Sep. 29, 2017,10-2017-0133853, filed in the Republic of Korea on Oct. 16, 2017, and10-2017-0150611, filed in the Republic of Korea on Nov. 13, 2017, all ofwhich are hereby expressly incorporated by reference into the presentapplication.

TECHNICAL FIELD

An embodiment relates to a controller and a motor assembly including thesame.

BACKGROUND ART

Motors are devices that convert electric energy into rotational energyusing a force applied to a conductor in a magnetic field. Recently, withthe expansion of the use of the motors, the role of the motor has becomeimportant. In particular, as vehicle electrification progresses rapidly,demands for the motor applied to a steering system, a braking system, aninterior system, and the like are greatly increasing.

In the case of such a motor for a vehicle, a motor assembly including acontroller capable of controlling the motor may be provided in thevehicle.

Since a high current is used in the controller, a heat-generationproblem is emerging. For example, in the case of a substrate used in thecontroller, a direct current (DC) power circuit, a control circuit, andan inverter circuit are disposed on the substrate. In addition, aheat-generation problem occurs in the substrate as the high current isapplied thereto. When the size of the substrate is increased to solvesuch a heat-generation problem, it is difficult to reduce the size andweight of the motor assembly.

Accordingly, there is a need for a motor assembly that is compact andsolves a heat-generation problem occurring in the substrate.

Further, since the size of a controller is limited due to the user’srequest, there is a need for a motor assembly in which placement ofelements and assembly of the elements within a limited size may besimplified.

SUMMARY

An embodiment is directed to providing a controller and a motor assemblyin which a heat-generation problem may be solved while miniaturizationand lightweighting are implemented.

An embodiment is also directed to providing a controller and a motorassembly in which some components may be shared.

Objectives to be achieved by the embodiments of the present inventionare not limited to the above-described objectives, and other objectiveswhich are not described above may be clearly understood by those skilledin the art through the following specification.

One aspect of the present invention provides a controller including acontroller housing, a controller cover disposed on an opening of thecontroller housing, a differential-mode (DM) filter unit disposed abovethe controller cover, a common-mode (CM) filter unit disposed above theDM filter unit, a power module unit disposed below the controller cover,a substrate disposed below the power module unit, and a first connectorand a second connector each having one side disposed on the substratethrough the controller cover, wherein the power module unit includes abracket, and a power module disposed between the bracket and thecontroller cover, wherein one surface of the power module is pressedagainst the controller cover, which is made of a metal material, by thebracket.

The power module may include a power module body, a plurality of firstpins arranged to protrude downward from one side of the power modulebody, and five terminal pins arranged to protrude downward from theother side of the power module body, wherein an end portion of the firstpin may be coupled to the substrate.

The bracket may include a bracket body having a cavity in which thepower module is disposed and three fourth bosses protruding downwardformed therein and three fourth terminals each having one side disposedto be exposed inside each of the fourth bosses and the other sidedisposed on the bracket body to protrude downward.

The bracket may further include a plate disposed below the bracket bodyto cross the cavity.

The bracket may further include at least two hooks protruding from thebracket body, and the power module may be fixed to the bracket by thehooks.

The hooks may be disposed to be spaced apart from each other atpredetermined intervals on the basis of a virtual line L passing througha center of the power module.

A second groove may be formed on a lower surface of the controller coversuch that an end portion of each of the hooks is disposed therein.

The bracket may further include a fourth protruding part protrudingdownward from the bracket body, and the fourth protruding part may bedisposed adjacent to the first pin.

A protruding height of the first pin may be greater than a protrudingheight of the fourth protruding part.

A heat transfer member may be further disposed between the power modulebody and the controller cover.

The fourth terminal may include a fourth body disposed horizontally, afourth frame formed to protrude downward from an end portion of one sideof the fourth body, and a fourth end portion bent at an end portion ofthe other side of the fourth body and disposed inside the fourth boss,wherein the fourth frame may be in contact with the terminal pin.

A sixth hole may be formed in the fourth end portion.

Another aspect of the present invention provides a motor assemblyincluding a controller and a motor, wherein the controller includes acontroller housing, a controller cover disposed on an opening of thecontroller housing, a differential-mode (DM) filter unit disposed abovethe controller cover, a common-mode (CM) filter unit disposed above theDM filter unit, a power module unit disposed below the controller cover,a substrate disposed below the power module unit, and a first connectorand a second connector each having one side disposed on the substratethrough the controller cover, wherein the power module unit includes abracket and a power module disposed between the bracket and thecontroller cover, wherein one side of the power module is pressedagainst the controller cover, which is made of a metal material, by thebracket.

The motor may include a rotation shaft, a rotor disposed outside therotation shaft, a stator disposed outside the rotor; a bus bar disposedabove the stator, a motor housing accommodating the rotor, the stator,and the bus bar, and a motor cover disposed on an opening of the motorhousing, wherein the bus bar may include a bus-bar body and a bus-barterminal, the bracket may include a bracket body having a cavity inwhich the power module is disposed and three fourth bosses protrudingdownward formed therein and three fourth terminals each having one sidedisposed to be exposed inside each of the fourth bosses and the otherside disposed on the bracket body to protrude downward, and one side ofthe bus-bar terminal may be coupled to a sixth hole of the fourthterminal.

Still another aspect of the present invention provides a controllerincluding a controller housing, a controller cover disposed on anopening of the controller housing, a differential-mode (DM) filter unitdisposed above the controller cover, a common-mode (CM) filter unitdisposed above the DM filter unit, a power module unit disposed belowthe controller cover, a substrate disposed below the power module unit,and a first connector and a second connector each having one sidedisposed on the substrate through the controller cover, wherein thepower module unit includes a bracket and a power module disposed betweenthe bracket and the controller cover, wherein the power module includesa power module body, a plurality of first pins arranged to protrudedownward from one side of the power module body, five terminal pinsarranged to protrude downward from the other side of the power modulebody, and a third protrusion protruding from an end portion of each ofthree terminal pins among the terminal pins, wherein an end portion ofthe third protrusion is coupled to the substrate.

An end portion of the first pin may be coupled to the substrate.

One surface of the power module may be pressed against the controllercover, which is made of a metal material, by the bracket.

The bracket may include a bracket body having a cavity in which thepower module is disposed and three fourth bosses protruding downwardformed therein and a fourth terminal having one side disposed to beexposed inside each of the fourth bosses and the other side disposed onthe bracket body to protrude downward.

The fourth terminal may be in contact with the terminal pin on which thethird protrusion is formed.

The bracket may further include a plate disposed below the bracket bodyto cross the cavity.

The bracket may further include at least two hooks protruding from thebracket body, and the power module may be fixed to the bracket by thehooks.

The hooks may be disposed to be spaced apart from each other atpredetermined intervals on the basis of a virtual line L passing througha center of the power module.

A second groove may be formed on a lower surface of the controller coversuch that an end portion of the hook is disposed therein.

The bracket may further include a fourth protruding part protrudingdownward from the bracket body, and the fourth protruding part may bedisposed adjacent to the first pin.

A protruding height of the first pin may be greater than a protrudingheight of the fourth protruding part.

The fourth terminal may include a fourth body disposed horizontally, afourth frame formed to protrude downward from an end portion of one sideof the fourth body, and a fourth end portion bent at an end portion ofthe other side of the fourth body and disposed inside the fourth boss,wherein the fourth frame may be in contact with the terminal pin.

A sixth hole may be formed in the fourth end portion.

A heat transfer member may be further disposed between the power modulebody and the controller cover.

A width of the third protrusion may be less than that of the terminalpin.

Yet another aspect of the present invention provides a motor assemblyincluding a controller and a motor, wherein the controller includes acontroller housing, a controller cover disposed on an opening of thecontroller housing, a differential-mode (DM) filter unit disposed abovethe controller cover, a common-mode (CM) filter unit disposed above theDM filter unit, a power module unit disposed below the controller cover,a substrate disposed below the power module unit, and a first connectorand a second connector each having one side disposed on the substratethrough the controller cover, wherein the power module unit includes abracket and a power module disposed between the bracket and thecontroller cover, wherein the power module includes a power module body,a plurality of first pins arranged to protrude downward from one side ofthe power module body, five terminal pins arranged to protrude downwardfrom the other side of the power module body, and a third protrusionprotruding from an end portion of each of three terminal pins among theterminal pins, wherein an end portion of the third protrusion is coupledto the substrate.

A width of the third protrusion may be less than that of the terminalpin.

One surface of the power module may be pressed against the controllercover, which is made of a metal material, by the bracket.

The motor may include a rotation shaft, a rotor disposed outside therotation shaft, a stator disposed outside the rotor; a bus bar disposedabove the stator, a motor housing accommodating the rotor, the stator,and the bus bar, and a motor cover disposed on an opening of the motorhousing, wherein the bus bar may include a bus-bar body and a bus-barterminal, the bracket may include a bracket body having a cavity inwhich the power module is disposed and three fourth bosses protrudingdownward formed therein and three fourth terminals each having one sidedisposed to be exposed inside each of the fourth bosses and the otherside disposed on the bracket body to protrude downward, and one side ofthe bus-bar terminal may be coupled to a sixth hole of the fourthterminal.

The fourth terminal may be in contact with the terminal pin on which thethird protrusion is formed.

Yet another aspect of the present invention provides a motor controllerincluding a substrate, a controller housing disposed on the substrate, acommon-mode (CM) filter unit disposed between the substrate and thecontroller housing, a differential-mode (DM) filter unit disposed belowthe CM filter unit, a controller cover disposed between the substrateand the DM filter unit, a power module unit disposed between thesubstrate and the controller cover, and a connector unit coupled to thesubstrate, wherein the power module unit includes a power module and amold unit surrounding the power module, wherein the mold unit includes aboss part protruding from one side thereof.

The power module may include a power module body, a first pin coupled toone side of the power module body, and a terminal part coupled to theother side of the power module body, wherein an end portion of the firstpin may be coupled to the substrate.

The terminal part may include two first power module terminalsprotruding toward an outside of the mold unit from the other side of thepower module body and three second power module terminals each havingone side connected to the other side of the power module body.

Each of the second power module terminals may include a body having oneside end portion connected to the power module body, an end portion bentat the other side end portion of the body and disposed inside the bosspart, and a hole formed in the end portion.

The boss part may be branched into three parts from the mold unit.

The boss part may protrude toward the substrate, and the other side ofthe second power module terminal may be disposed to be exposed insidethe boss part.

A space may be formed at the inside of the boss part, and the space maybe formed to pass through from a lower portion to an upper portion ofthe boss part.

A protruding part protruding downward may be further formed at a lowerend of the boss part.

A width of one side of the mold unit on which the boss part is formedmay be less than a width of the other side disposed to face the oneside.

One side of the first power module terminal, which protrudes toward theoutside of the mold unit, may be disposed to protrude downward.

The power module body may further include a protruding region protrudingfrom one side thereof, and the protruding region may be disposed betweenthe first power module terminals.

The other side of the first power module terminal may be connected tothe protruding region.

The controller cover may be made of a metal material.

Yet another aspect of the present invention provides a motor assemblyincluding a motor controller and a motor, wherein the motor controllerincludes a substrate, a controller housing disposed on the substrate, acommon-mode (CM) filter unit disposed between the substrate and thecontroller housing, a differential-mode (DM) filter unit disposed belowthe CM filter unit, a controller cover disposed between the substrateand the DM filter unit, a power module unit disposed between thesubstrate and the controller cover, and a connector unit coupled to thesubstrate, wherein the power module unit includes a power module and amold unit surrounding the power module, wherein the mold unit includes aboss part protruding from one side thereof.

The motor may include a rotation shaft, a rotor disposed outside therotation shaft, a stator disposed outside the rotor; a bus bar disposedabove the stator, a motor housing accommodating the rotor, the stator,and the bus bar, and a motor cover disposed on an opening of the motorhousing, wherein the bus bar may include a bus-bar body and a bus-barterminal, and the power module may include a power module body, a firstpin coupled to one side of the power module body, two first power moduleterminals disposed to protrude downward from the other side of the powermodule body, and three second power module terminals each having oneside connected to the other side of the power module body, wherein oneside of the bus-bar terminal may be coupled to a hole of the secondpower module terminal.

The connector unit may include a first connector and a second connector,and each of the first connector and the second connector may passthrough the controller cover.

One side of the first connector may be coupled to the substrate and theother side thereof may be disposed inside one boss of three bossesformed in the controller housing, and one side of the second connectormay be coupled to the substrate and the other side thereof may bedisposed inside another boss of the three bosses formed in thecontroller housing.

ADVANTAGEOUS EFFECTS

A motor assembly including a controller according to an embodiment cansolve a heat-generation problem by pressing a power module generating agreat amount of heat against a controller cover made of a metalmaterial.

Further, space can be utilized and material costs and mold costs can bereduced by placing a mold unit in a power module through an insertinjection method.

Further, the size of a power module can be increased by placing a moldunit in a power module through an insert injection method, therebyimproving a degree of the design freedom of the power module.Furthermore, in the power module having an increased size, the contactarea with a controller cover can be increased to improve heatdissipation performance.

Further, a controller and a motor assembly can be implemented in acompact structure by vertically disposing an element having a largesize.

Further, whenever the different types of motors are coupled to acontroller, only a substrate can be replaced together with the motor sothat some components of the controller can be shared.

Further, the reverse connection of power can be prevented by using ametal-oxide-semiconductor field-effect transistor (MOSFET) disposed onthe substrate. Accordingly, the reliability of the stability of a motorassembly can be improved.

Various and beneficial advantages and effects of the embodiment are notlimited to the above descriptions and will be more easily understood ina process of describing specific embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a motor assembly according to anembodiment.

FIG. 2 is an exploded perspective view of the motor assembly accordingto the embodiment in which a power module unit according to a firstembodiment is disposed.

FIG. 3 is a cross-sectional view illustrating the motor assemblyaccording to the embodiment.

FIG. 4 is a plan view of the motor assembly according to the embodiment.

FIG. 5 is a perspective view illustrating a controller housing of themotor assembly according to the embodiment.

FIG. 6 is a bottom perspective view illustrating the controller housingof the motor assembly according to the embodiment.

FIG. 7 is a perspective view illustrating a common-mode (CM) filter unitof the motor assembly according to the embodiment.

FIG. 8 is a bottom perspective view illustrating the CM filter unit ofthe motor assembly according to the embodiment.

FIG. 9 is a view illustrating a second terminal, a (2-1)th terminal, a(2-2)th terminal, a CM filter, and a first capacitor of the CM filterunit according to the embodiment.

FIG. 10 is a view illustrating an arrangement relationship between afirst terminal of the controller housing and the second terminal of theCM filter unit of the motor assembly according to the embodiment.

FIG. 11 is a view illustrating an arrangement relationship between afirst protrusion of the controller housing and a first hole of the CMfilter unit in the motor assembly according to the embodiment.

FIG. 12 is a view illustrating a relationship in which a firstprotrusion of the controller housing of the motor assembly according tothe embodiment is fused and fixed to a first hole.

FIG. 13 is a perspective view illustrating a differential-mode (DM)filter unit of the motor assembly according to the embodiment.

FIG. 14 is an exploded perspective view illustrating the DM filter unitof the motor assembly according to the embodiment.

FIG. 15 is a bottom perspective view illustrating the DM filter unit ofthe motor assembly according to the embodiment.

FIG. 16 is a plan view illustrating the DM filter unit of the motorassembly according to the embodiment.

FIG. 17 is a view illustrating a third terminal, a (3-1)th terminal, a(3-2)th terminal, a (3-3)th terminal, a DM filter, and a secondcapacitor of the DM filter unit according to the embodiment.

FIG. 18 is a bottom perspective view illustrating the third terminal,the (3-1)th terminal, the (3-2)th terminal, the (3-3)th terminal, the DMfilter, and the second capacitor of the DM filter unit according to theembodiment.

FIG. 19 is a view illustrating a state in which the CM filter unit andthe DM filter unit of the motor assembly according to the embodiment arecoupled to each other.

FIG. 20 is a perspective view illustrating a controller cover of themotor assembly according to the embodiment.

FIG. 21 is a bottom perspective view illustrating the controller coverof the motor assembly according to the embodiment.

FIG. 22 is a bottom view illustrating the controller cover of the motorassembly according to the embodiment.

FIG. 23 is an enlarged view of region A in FIG. 3 .

FIG. 24 is a perspective view illustrating the power module unitaccording to the first embodiment of the motor assembly according to theembodiment.

FIG. 25 is a bottom perspective view illustrating the power module unitaccording to the first embodiment of the motor assembly according to theembodiment.

FIG. 26 is an exploded perspective view illustrating the power moduleunit according to the first embodiment of the motor assembly accordingto the embodiment.

FIG. 27 is a plan view illustrating the power module unit according tothe first embodiment of the motor assembly according to the embodiment.

FIG. 28 is a side view illustrating the power module unit according tothe first embodiment of the motor assembly according to the embodiment.

FIG. 29 is a view illustrating a power module of the power module unitaccording to the first embodiment.

FIG. 30 is a view illustrating a bracket of the power module unitaccording to the first embodiment.

FIG. 31 is a view illustrating a fourth terminal of the power moduleunit according to the first embodiment.

FIG. 32 is a view illustrating a substrate of the motor assemblyaccording to the embodiment.

FIG. 33 is a view illustrating a first connector of the motor assemblyaccording to the embodiment.

FIG. 34 is a view illustrating a second connector of the motor assemblyaccording to the embodiment.

FIG. 35 is a view illustrating a bus-bar terminal of the motor assemblyaccording to the embodiment.

FIG. 36 is an exploded perspective view illustrating a motor accordingto the embodiment in which a power module unit according to a secondembodiment is disposed.

FIG. 37 is a perspective view illustrating the power module unitaccording to the second embodiment of the motor assembly according tothe embodiment.

FIG. 38 is a bottom perspective view illustrating the power module unitaccording to the second embodiment of the motor assembly according tothe embodiment.

FIG. 39 is a plan view illustrating the power module unit according tothe second embodiment of the motor assembly according to the embodiment.

FIG. 40 is a view illustrating a power module of the power module unitaccording to the second embodiment.

DETAILED DESCRIPTION

Hereinafter, exemplary embodiments of the present invention will bedescribed in detail with reference to the accompanying drawings.

However, the technical spirit of the present invention is not limited tosome embodiments which will be described herein and may be realizedusing various other embodiments, and at least one element of theembodiments may be selectively coupled, substituted, and used to realizethe technical spirit within the range of the technical spirit.

Further, unless clearly and specifically defined otherwise by context,all terms (including technical and scientific terms) used herein can beinterpreted as having customary meanings to those skilled in the art,and meanings of generally used terms, such as those defined in commonlyused dictionaries, will be interpreted by considering contextualmeanings of the related technology.

Further, the terms used in the embodiments of the present invention areprovided only to describe embodiments of the present invention and notfor limiting the present invention.

In the present specification, the singular forms include the pluralforms unless the context clearly indicates otherwise, and the phrase “atleast one element (or one or more elements) of an element A, an elementB, and an element C” should be understood as including the meaning of atleast one of all combinations being obtained by combining the element A,the element B, and the element C.

Further, in describing elements of the embodiments of the presentinvention, the terms such as first, second, A, B, (a), (b), and the likemay be used.

These terms are merely for distinguishing one element from otherelements, and the essential, order, sequence, and the like ofcorresponding elements are not limited by the terms.

In addition, when an element is referred to as being “connected orcoupled” to another element, such a description may include both a casein which the element is directly connected or coupled to anotherelement, and a case in which the element is connected or coupled toanother element with still another element disposed therebetween.

Further, when an element is described as being formed or disposed “on(above)” or “under (below)” another element, the term “on (above)” or“under (below)” includes a case in which two elements are in directcontact with each other and a case in which one or more elements are(indirectly) disposed between two elements. Also, being “above (on) orbelow (beneath)” may include not only an upward direction but also adownward direction on the basis of one element.

Hereinafter, the embodiments will be described in detail with referenceto the accompanying drawings. However, equal or corresponding elementswill be referred to as the same reference numerals regardless of drawingsigns, and a repetitive description thereof will be omitted.

FIG. 1 is a perspective view of a motor assembly according to anembodiment.

A motor assembly 1 according to the embodiment may include a controller2 and a motor 3 according to the embodiment. Here, the controller 2 is amotor controller configured to control the motor 3.

Here, the motor 3 may be detachably disposed at a lower portion of thecontroller 2. Accordingly, various motors 3 may be connected to thecontroller 2 even when some components of the controller 2 are shared.Here, a substrate may be replaceably disposed between the controller 2and the motor 3. Thus, whenever the different types of motors 3 arecoupled, only the substrate may be replaced together with the motor 3 sothat some components of the controller 2 may be shared.

FIG. 2 is an exploded perspective view of the motor assembly accordingto the embodiment in which a power module unit according to a firstembodiment is disposed, FIG. 3 is a cross-sectional view illustratingthe motor assembly according to the embodiment, and FIG. 4 is a planview of the motor assembly according to the embodiment. Here, FIG. 3 maybe a cross-sectional view taken along line A-A in FIG. 1 .

Referring to FIGS. 1 to 3 , the controller 2 may include a controllerhousing 100, a common-mode (CM) filter unit 200, a differential-mode(DM) filter unit 300, a controller cover 400, a power module unit 500according to the first embodiment, a substrate 600, and a connectorunit. Here, the connector unit may include a first connector 700 and asecond connector 800. Here, the controller housing 100 may be referredto as a first housing. In addition, the controller cover 400 may bereferred to as a first cover unit.

The connector unit may pass through the controller cover 400. Here, theconnector unit may pass through the controller cover 400 to be spacedapart from an outer side of the power module unit 500. For example, oneside of each of the first connector 700 and the second connector 800disposed through the controller cover 400 may be disposed on thesubstrate 600. As illustrated in FIG. 4 , the other side of the firstconnector 700 may be disposed inside one boss of three bosses formed inthe controller housing 100, and the other side of the second connector800 may be disposed inside another boss of the three bosses.

The controller 2 receives power through an external connector. Inaddition, the power is transferred to the substrate 600 through the CMfilter unit 200 and the DM filter unit 300. In addition, the power inwhich the reverse connection is prevented at the substrate 600 istransferred to the DM filter unit 300 and then supplied to the powermodule unit 500 and the substrate 600.

The controller housing 100 and the controller cover 400 disposed on anopening of the controller housing 100 may form an outer shape of thecontroller 2. Here, the controller housing 100 may be disposed on thesubstrate 600.

An accommodation space may be formed therein by combining the controllerhousing 100 and the controller cover 400. The CM filter unit 200 and theDM filter unit 300 may be disposed in the accommodation space.

FIG. 5 is a perspective view illustrating the controller housing of themotor assembly according to the embodiment, and FIG. 6 is a bottomperspective view illustrating the controller housing of the motorassembly according to the embodiment.

Referring to FIGS. 5 and 6 , the controller housing 100 may include acontroller housing body 110 and a first terminal 120. Here, thecontroller housing body 110 may be referred to as a first body. Inaddition, the first terminal 120 may be referred to as a controllerhousing terminal.

The controller housing body 110 may be formed in a cylindrical shapesuch that an accommodation space is formed therein. Openings may beformed in the controller housing body 110 for the arrangement of the CMfilter unit 200 and the DM filter unit 300.

A first boss 111, a second boss 112, a third boss 113, a plurality offirst protrusions 114, and a first protruding part 115 may be formed inthe controller housing body 110. Here, the first boss 111, the secondboss 112, the third boss 113, the first protrusions 114, and the firstprotruding part 115 may be integrally formed with the controller housingbody 110.

The first boss 111, the second boss 112, and the third boss 113 may beformed to protrude from an upper portion of the controller housing body110. Here, the first boss 111, the second boss 112, and the third boss113 may be disposed to be spaced apart from each other.

A space may be formed in each of the first boss 111, the second boss112, and the third boss 113, and an external connector (not shown),through which power or signals from the outside may be transmitted andreceived, may be connected to each of the first boss 111, the secondboss 112, and the third boss 113. Accordingly, each of the first boss111, the second boss 112, and the third boss 113 may be formed invarious shapes depending on the shape of the external connector.

As illustrated in FIG. 6 , the plurality of first protrusions 114 may beformed to protrude downward from an inner surface 116 of a lower side ofthe controller housing body 110. Thus, the CM filter unit 200 may becoupled to a lower portion of the controller housing 100 through thefirst protrusions 114.

The first protruding part 115 may be formed to protrude downward from anend portion of the controller housing body 110. In addition, the firstprotruding part 115 may be coupled to the controller cover 400.

As illustrated in FIG. 4 , two first terminals 120 may be provided.

The first terminal 120 may be disposed in the controller housing body110 through an insert injection method. As illustrated in FIG. 4 , thefirst terminal 120 may be disposed inside the first boss 111. Here, thefirst terminal 120 may be made of a metal material. Accordingly, thefirst terminal 120 may be formed by press processing a sheet metal suchas a copper plate.

Power may be applied to the first terminal 120 through the externalconnector coupled to the first boss 111.

Referring to FIGS. 4 and 6 , one side of the first terminal 120 may bedisposed inside the first boss 111, and an end portion 121 of the otherside of the first terminal 120 may be disposed to protrude downward fromthe inner surface 116 of the controller housing body 110. As illustratedin FIG. 6 , the first terminal 120 may be fixed to an inside of thecontroller housing body 110 by a coupling member 4 such as a bolt or ascrew.

Meanwhile, the controller housing body 110 in which the first boss 111,the second boss 112, and the third boss 113 are formed may be made of asynthetic resin material. Accordingly, the controller housing body 110may be formed in various shapes according to a design thereof and enablelightweighting of the motor assembly 1.

FIG. 7 is a perspective view illustrating the CM filter unit of themotor assembly according to the embodiment, FIG. 8 is a bottomperspective view illustrating the CM filter unit of the motor assemblyaccording to the embodiment, FIG. 10 is a view illustrating anarrangement relationship between the first terminal of the controllerhousing and a second terminal of the CM filter unit in the motorassembly according to the embodiment, FIG. 11 is a view illustrating anarrangement relationship between the first protrusion of the controllerhousing and a first hole of the CM filter unit in the motor assemblyaccording to the embodiment, and FIG. 12 is a view illustrating arelationship in which the first protrusion of the controller housing ofthe motor assembly according to the embodiment is fused and fixed to thefirst hole.

The CM filter unit 200 may be disposed above the DM filter unit 300. TheCM filter unit 200 may be disposed between the controller housing 100and the substrate 600. Here, the CM filter unit 200 may be disposedbelow the inner surface 116 of the controller housing 100.

Referring to FIGS. 7 to 9 , the CM filter unit 200 may include a CMfilter unit body 210, a second terminal 220, a (2-1)th terminal 230, a(2-2)th terminal 240, a CM filter 250, and two first capacitors 260.First holes 225, 235, and 245 may be formed in the second terminal 220,the (2-1)th terminal 230, and the (2-2)th terminal 240, respectively.Here, the CM filter unit body 210 may be referred to as a second body,and the first capacitors 260 may be referred to as CM filter unitcapacitors. In addition, the first holes 225, 235, and 245 may bereferred to as fixing holes.

The CM filter unit body 210 may be made of a synthetic resin material,and the second terminal 220, the (2-1)th terminal 230, and the (2-2)thterminal 240 may be made of a metal material. Accordingly, the secondterminal 220, the (2-1)th terminal 230, and the (2-2)th terminal 240 maybe disposed in the CM filter unit body 210 through an insert injectionmethod. Here, the second terminal 220, the (2-1)th terminal 230, and the(2-2)th terminal 240 may be preferentially formed by press processing asheet metal such as a copper plate.

The CM filter unit body 210 may be formed in a ⊏ shape.

A second hole 211 may be formed in the CM filter unit body 210. Here,the second hole 211 may be referred to as a guide hole.

The first protrusion 114 of the controller housing 100 may be disposedin the second hole 211. Accordingly, since the CM filter unit body 210may be disposed in the controller housing 100 in the manner of insertingthe second hole 211 into the first protrusion 114, the assembly positionof the CM filter unit 200 is restricted. Further, the coupling of thefirst protrusion 114 and the second hole 211 prevents the movement ofthe CM filter unit 200 in a horizontal direction.

The second terminal 220 has one side in contact with the end portion 121of the other side of the first terminal 120 and the other side incontact with the CM filter 250 to be electrically connected. Here, twosecond terminal 220 may be provided to correspond to the number of thefirst terminals 120.

The second terminal 220 may include a second body 221 disposedhorizontally, a second frame 222 protruding downward from an end portionof one side the second body 221, a second bent portion 223 formed bybending an end portion of the other side of the second body 221, asecond end portion 224, and a first hole 225.

The second frame 222, which is an end portion of one side of the secondterminal 220 in contact with the first terminal 120, may be formed bybending one side of the second body 221 downward. As illustrated in FIG.10 , the end portion 121 of one side of the first terminal 120, which isdisposed to protrude downward from the inner surface 116, is in contactwith the second frame 222 of the second terminal 220, which is bentdownward. Here, the contact force between the end portion 121 of oneside of the first terminal 120 and the second frame 222 of the secondterminal 220 may be improved through a fusing process.

The second bent portion 223, which is one of end portions of the otherside of the second terminal 220, is connected to a first wire 251disposed in the CM filter 250. To this end, the second bent portion 223formed on the other side of the second body 221 may be formed in a hookshape, and the first wire 251 may be electrically connected to the otherside of the second terminal 220 through a fusing process. Here, thefirst wire 251 may be referred to as a first CM filter wire.

The second end portion 224 branched from the other side of the secondterminal 220 is electrically connected to a second wire 261 disposed onthe first capacitor 260. For example, the second end portion 224 may beformed in a shape in which two protrusions are disposed to be spacedapart from each other, and as illustrated in FIG. 8 , the second wire261 may be disposed between the protrusions. Here, the second wire 261may be electrically connected to the second end portion 224 of thesecond terminal 220 through a fusing process. Here, the second wire 261may be referred to as a second CM filter wire.

Referring to FIGS. 7 to 9 , the first hole 225 may be formed in thesecond terminal 220.

As illustrated in FIG. 11 , the first protrusion 114 of the controllerhousing 100 may be disposed in the first hole 225. Accordingly, thefirst hole 225 may be coupled to the first protrusion 114 in the mannerof inserting the first hole 225 into the first protrusion 114.

Then, an end portion of the first protrusion 114 may be fused to thesecond terminal 220 by heating, as illustrated in FIG. 12 . Accordingly,the CM filter unit 200 may be fixed to the controller housing 100. Here,since the first protrusion 114 is made of a synthetic resin material andthe second terminal 220 is made of a metal material, thermal fusion ispossible.

One side of the (2-1)th terminal 230 is bent toward the DM filter unit300, and the other side of the (2-1)th terminal 230 is electricallyconnected to the CM filter 250 by being in contact therewith. Here, two(2-1)th terminals 230 may be provided.

The (2-1)th terminal 230 may include a (2-1)th body 231 disposedhorizontally, a (2-1)th frame 232 protruding downward from an endportion of one side of the (2-1)th body 231, a (2-1)th bent portion 233formed by bending an end portion of the other side of the (2-1)th body231, and a first hole 235.

The (2-1)th frame 232 may be formed by bending the end portion of oneside of the (2-1)th body 231 downward. The (2-1)th frame 232, which isan end portion of one side of the (2-1)th terminal 230 bent downward,may be coupled to a third terminal 320 of the DM filter unit 300. Here,two (2-1)th protrusions 234 may be disposed on the (2-1)th frame 232 tobe spaced apart from each other. Accordingly, the coupling force andcontact force between the (2-1)th protrusion 234 and the third terminal320 may be improved.

The other side of the (2-1)th terminal 230 is connected to the firstwire 251 disposed in the CM filter 250. To this end, the (2-1)th bentportion 233 of the (2-1)th terminal 230 may be formed in a hook shape,and the first wire 251 may be electrically connected to the other sideof the (2-1)th terminal 230 through a fusing process.

Referring to FIGS. 7 to 9 , the first hole 235 may be formed in the(2-1)th terminal 230.

As illustrated in FIG. 11 , the first protrusion 114 of the controllerhousing 100 may be disposed in the first hole 235. Accordingly, thefirst hole 235 may be coupled to the first protrusion 114 in the mannerof inserting the first hole 235 into the first protrusion 114.

Then, an end portion of the first protrusion 114 may be fused to the(2-1)th terminal 230 by heating, as illustrated in FIG. 12 .Accordingly, the CM filter unit 200 may be fixed to the controllerhousing 100.

The (2-2)th terminal 240 may perform a grounding function.

One side of the (2-2)th terminal 240 is bent toward the DM filter unit300, and the other side of the (2-2)th terminal 240 is electricallyconnected to the first capacitor 260 by being in contact therewith.Here, an end portion 242 of the other side of the (2-2)th terminal 240may be branched to be connected to each of the two first capacitor 260.

The (2-2)th terminal 240 may include a (2-2)th body 241 disposedhorizontally, a (2-2)th frame 242 protruding downward from an endportion of one side of the (2-2)th body 241, a (2-2)th end portion 244,and a first hole 245.

The (2-2)th frame 242 may be formed by bending one side of the (2-2)thbody 241 downward. The (2-2)th frame 242, which is an end portion of oneside of the (2-2)th terminal 240 bent downward, may be coupled to a(3-3)th terminal 350 of the DM filter unit 300. Here, two (2-2)thprotrusions 243 may be further disposed on the (2-2)th frame 242 to bespaced apart from each other. Accordingly, the coupling force andcontact force between the (2-2)th protrusion 243 and a (3-4)th terminal360 may be improved.

The other side of the (2-2)th terminal 240 is electrically connected tothe second wire 261 disposed in the first capacitor 260. To this end,the (2-2)th end portion 244, which is an end portion of the other sideof the (2-2)th terminal 240, may be formed in a shape in which twoprotrusions are disposed to be spaced apart from each other, and thesecond wire 261 may be disposed between the protrusions, as illustratedin FIG. 8 . Here, the second wire 261 may be electrically connected tothe other side of the (2-2)th terminal 240 through a fusing process.

Referring to FIGS. 7 to 9 , the first hole 245 may be formed in the(2-2)th terminal 240.

As illustrated in FIG. 11 , the first protrusion 114 of the controllerhousing 100 may be disposed in the first hole 245. Accordingly, thefirst hole 245 may be coupled to the first protrusion 114 in the mannerof inserting the first hole 245 into the first protrusion 114.

Then, an end portion of the first protrusion 114 may be fused to the(2-2)th terminal 240 by heating as illustrated in FIG. 12 . Accordingly,the CM filter unit 200 may be fixed to the controller housing 100.

The CM filter 250 may be disposed between the second terminal 220 andthe (2-1)th terminal 230. Here, the CM filter 250 may be disposed abovethe CM filter unit body 210 and may be disposed between two legs of theCM filter unit body 210 disposed horizontally to be spaced apart fromeach other.

The CM filter 250 may reduce a CM noise. For example, the secondterminal 220 electrically connected to the first terminal 120 may beused as a power line, and the CM filter 250 may reduce the CM noise,which is caused by a CM current component, among conductive noisesgenerated through the second terminal 220 being used as the power line.

As illustrated in FIG. 7 , a plurality of first wires 251 may bearranged in the CM filter 250, and the first wires 251 may beelectrically connected to the second terminals 220 and the (2-1)thterminal 230 at the space between the legs.

The first capacitor 260 may be disposed below the CM filter unit body210. Here, a plurality of second wires 261 arranged in the firstcapacitor 260 may be electrically connected to each of the secondterminal 220 and the (2-2)th terminal 240.

FIG. 13 is a perspective view illustrating the DM filter unit of themotor assembly according to the embodiment, FIG. 14 is an explodedperspective view illustrating the DM filter unit of the motor assemblyaccording to the embodiment, FIG. 15 is a bottom perspective viewillustrating the DM filter unit of the motor assembly according to theembodiment, FIG. 16 is a plan view illustrating the DM filter unit ofthe motor assembly according to the embodiment, FIG. 17 is a viewillustrating a third terminal, a (3-1)th terminal, a (3-2)th terminal, a(3-3)th terminal, a DM filter, and a second capacitor of the DM filterunit according to the embodiment, FIG. 18 is a bottom perspective viewillustrating the third terminal, the (3-1)th terminal, the (3-2)thterminal, the (3-3)th terminal, the DM filter, and the second capacitorof the DM filter unit according to the embodiment, and FIG. 19 is a viewillustrating a state in which the CM filter unit and the DM filter unitof the motor assembly according to the embodiment are coupled to eachother.

The DM filter unit 300 may be disposed above the controller cover 400.Here, the DM filter unit 300 may be disposed below the CM filter unit200.

Referring to FIGS. 13 to 17 , the DM filter unit 300 may include a DMfilter unit body 310, the third terminal 320, a (3-1)th terminal 330, a(3-2)th terminal 340, the (3-3)th terminal 350, the (3-4)th terminal360, a DM filter 370, and three second capacitors 380. Here, the DMfilter unit body 310 may be referred to as a third body, and the secondcapacitors 380 may be referred to as DM filter unit capacitors.

The DM filter unit body 310 may be made of a synthetic resin material,and the third terminal 320, the (3-1)th terminal 330, the (3-2)thterminal 340, the (3-3)th terminal 350, and the (3-4)th terminal 360 maybe made of a metal material. Accordingly, the third terminal 320, the(3-1)th terminal 330, the (3-2)th terminal 340, the (3-3)th terminal350, and the (3-4)th terminal 360 may be disposed in the DM filter unitbody 310 through an insert injection method. Here, the third terminal320, the (3-1)th terminal 330, the (3-2)th terminal 340, the (3-3)thterminal 350, and the (3-4)th terminal 360 may be preferentially formedby press processing a sheet metal such as a copper plate.

A fourth hole 311 and a plurality of second protruding parts 312 may beformed in the DM filter unit body 310. Here, the fourth hole 311 may bereferred to as a fastening hole.

The DM filter unit 300 may be fixed to the controller cover 400 by thecoupling member 4 being disposed in the fourth hole 311.

The second protruding part 312 may be formed to protrude downward fromthe DM filter unit body 310. Here, the second protruding parts 312 maybe integrally formed with the DM filter unit body 310.

The second protruding parts 312 may be disposed to pass through thecontroller cover 400. Accordingly, the third terminal 320, the (3-1)thterminal 330, the (3-2)th terminal 340, and the (3-3)th terminal 350,each having one region disposed inside the second protruding part 312,may be insulated from the controller cover 400.

The third terminal 320 electrically connects the (2-1)th terminal 230 tothe substrate 600. Here, two third terminals 320 may be provided. Inaddition, one region of the third terminal 320 may pass through thecontroller cover 400. To this end, a hole may be formed in thecontroller cover 400.

The third terminal 320 may include a third body 321 disposedhorizontally, a third frame 322 protruding downward from an end portionof one side of the third body 321, and a third hole 323.

The third hole 323 may be formed in each of the third bodies 321. Here,the third hole 323 may be referred to as a coupling hole.

As illustrated in FIG. 19 , the (2-1)th frame 232, which is an endportion of one side of the (2-1)th terminal 230, may be coupled to thethird hole 323.

When two third hole 323 are formed, the (2-1)th protrusions 234 formedon the (2-1)th frame 232 may be coupled to the third holes 323.Accordingly, the coupling force and contact force between the (2-1)thterminal 230 and the third terminal 320 may be improved.

One region of the third terminal 320 may be bent toward the substrate600. For example, the third frame 322, which is a bent end portion ofone side of the third terminal 320, may be formed by being bentdownward.

The third frame 322 of the third terminal 320 may be disposed toprotrude from an end portion of the second protruding part 312. Here,the second protruding part 312 is disposed to surround one region of thethird frame 322 so that the third terminal 320 is insulated from thecontroller cover 400.

In addition, an end portion of the third frame 322 exposed from thesecond protruding part 312 may be fixed to the substrate 600 throughsoldering.

One side of the (3-1)th terminal 330 is connected to the substrate 600,and the other side thereof is connected to the DM filter 370. Thus, the(3-1)th terminal 330 electrically connects the DM filter 370 to thesubstrate 600. Here, one region of the (3-1)th terminal 330 may passthrough the controller cover 400. To this end, a hole may be formed inthe controller cover 400.

The (3-1)th terminal 330 may include a (3-1)th body 331 disposedhorizontally, a (3-1)th frame 332 protruding downward from an endportion of one side of the (3-1)th body 331, and a (3-1)th end portion333 disposed at the other side of the (3-1)th body 331.

One region of the (3-1)th body 331 may be bent toward the substrate 600.For example, the (3-1)th frame 332, which is a bent end portion of oneside of the (3-1)th terminal 330, may be formed by bending one side ofthe (3-1)th body 331 downward.

The (3-1)th frame 332, which is an end portion of the (3-1)th terminal330, may be disposed to protrude from an end portion of the secondprotruding part 312. Here, the second protruding part 312 is disposed tosurround one region of the (3-1)th frame 332 so that the (3-1)thterminal 330 is insulated from the controller cover 400.

In addition, an end portion of the (3-1)th frame 332 exposed from thesecond protruding part 312 may be fixed to the substrate 600 throughsoldering.

The (3-1)th end portion 333, which is an end portion of the other sideof the (3-1)th terminal 330, is electrically connected to a third wire371 disposed in the DM filter 370. To this end, the (3-1)th end portion333 may be formed in a shape in which two protrusions are disposed to bespaced apart from each other, and as illustrated in FIG. 13 , the thirdwire 371 may be disposed between the protrusions. Here, the third wire371 may be electrically connected to the (3-1)th end portion 333 of the(3-1)th terminal 330 through a fusing process.

The (3-2)th terminal 340 allows the DM filter 370, the second capacitor380, the power module unit 500, and the substrate 600 to be electricallyconnected to each other.

The (3-2)th terminal 340 may include a (3-2)th body 341 disposedhorizontally, a (3-2)th frame 342 protruding downward from the (3-2)thbody 341, and a (3-2)th end portion 343 protruding upward from the(3-2)th body 341. Here, the (3-2)th frame 342 may include a (3-2-1)thframe 342 a having an end portion coupled to the power module unit 500,and a (3-2-2)th frame 342 b having an end portion coupled to thesubstrate 600. In addition, the (3-2)th end portion 343 may include a(3-2-1)th end portion 343 a coupled to the DM filter 370 and a (3-2-2)thend portion 343 b coupled to the second capacitor 380.

One region of the (3-2)th body 341 may be bent downward. For example,the (3-2)th frame 342, which is a bent end portion of one side of the(3-2)th terminal 340, may be formed by bending one side of the (3-2)thbody 341 downward.

Accordingly, the end portion of the (3-2-1)th frame 342 a that is oneportion of the (3-2)th frame 342 may be coupled to the power module unit500. In addition, the end portion of the (3-2-2)th frame 342 b which isanother portion of the (3-2)th frame 342 may be coupled to the substrate600. Here, a length of the (3-2-1)th frame 342 a is less than a lengthof the (3-2-2)th frame 342 b.

The (3-2)th frame 342 of the (3-2)th terminal 340 may pass through thecontroller cover 400. To this end, a hole may be formed in thecontroller cover 400.

Meanwhile, the (3-2)th frame 342 of the (3-2)th terminal 340 may bedisposed to protrude from an end portion of the second protruding part312. Here, the second protruding part 312 is disposed to surround oneregion of the (3-2)th frame 342 so that the (3-2)th terminal 340 that isdisposed to pass through the controller cover 400 is insulated from thecontroller cover 400.

In addition, an end portion of the (3-2-2)th frame 342 b exposed fromthe second protruding part 312 may be fixed to the substrate 600 throughsoldering.

The (3-2-1)th end portion 343 a, which is one of end portions of theother side of the (3-2)th terminal 340, is electrically connected to thethird wire 371 disposed in the DM filter 370. To this end, the (3-2-1)thend portion 343 a may be formed in a shape in which two protrusions aredisposed to be spaced apart from each other, and as illustrated in FIG.13 , the third wire 371 may be disposed between the protrusions. Here,the third wire 371 may be electrically connected to the (3-2-1)th endportion 343 a of the (3-1)th terminal 330 through a fusing process.Here, the third wire 371 may be referred to as a first DM filter wire.

The (3-2-2)th end portion 343 b, which is another one of the endportions of the other side of the (3-2)th terminal 340, is electricallyconnected to a fourth wire 381 disposed in the second capacitor 380. Forexample, the (3-2-2)th end portion 343 b may be formed in a shape inwhich two protrusions are disposed to be spaced apart from each other,and as illustrated in FIG. 13 , the fourth wire 381 may be disposedbetween the protrusions. Here, the fourth wire 381 may be electricallyconnected to the (3-2-2)th end portion 343 b of the (3-1)th terminal 330through a fusing process. Here, the fourth wire 381 may be referred toas a second DM filter wire.

The (3-3)th terminal 350 allows the second capacitor 380, the powermodule unit 500, and the substrate 600 to be electrically connected toeach other.

The (3-3)th terminal 350 may include a (3-3)th body 351 disposedhorizontally, a (3-3)th frame 352 protruding downward from the (3-3)thbody 351, and a (3-3)th end portion 353 protruding upward from the(3-3)th body 351.

One region of the (3-3)th body 351 may be bent downward. For example,the (3-3)th frame 352, which is a bent end portion of one side of the(3-3)th terminal 350, may be formed by bending one side of the (3-3)thbody 351 downward.

Here, the (3-3)th frame 352 may include a (3-3-1)th frame 352 a havingan end portion coupled to the substrate 600 to receive power, a(3-3-2)th frame 352 b having an end portion coupled to the substrate 600to transmit the power, and a (3-3-3)th frame 352 c having an end portioncoupled to the power module unit 500 to transmit the power.

Here, a length of the (3-3-3)th frame 352 c is less than a length of the(3-3-1)th frame 352 a. In addition, the length of the (3-3-1)th frame352 a may be the same as a length of the (3-3-2)th frame 352 b.

Further, the (3-3)th frame 352 of the (3-3)th terminal 350 may passthrough the controller cover 400. To this end, a hole may be formed inthe controller cover 400.

Further, the (3-3)th frame 352 of the (3-3)th terminal 350 may bedisposed to protrude from an end portion of the second protruding part312. Here, the second protruding part 312 is disposed to surround oneregion of the (3-3)th frame 352 so that the (3-3)th terminal 350 that isdisposed to pass through the controller cover 400 is insulated from thecontroller cover 400.

In addition, an end portion of the (3-3)th frame 352 exposed from thesecond protruding part 312 may be fixed to the substrate 600 throughsoldering.

The (3-3)th end portion 353, which is an end portion of the other sideof the (3-3)th terminal 350, is electrically connected to the fourthwire 381 disposed in the second capacitor 380. For example, the (3-3)thend portion 353 may be formed in a shape in which two protrusions aredisposed to be spaced apart from each other, and as illustrated in FIG.13 , the fourth wire 381 may be disposed between the protrusions. Here,the fourth wire 381 may be electrically connected to the (3-3)th endportion 353 of the (3-1)th terminal 330 through a fusing process.

The (3-4)th terminal 360 may be electrically connected to the (2-2)thterminal 240 and the controller cover 400.

One region of the (3-3)th terminal 350 may be cut to form the (3-4)thterminal 360. For example, the (3-4)th terminal 360 may be formed bypressing and cutting one region of the (3-3)th terminal 350 when the(3-3)th terminal 350 is disposed in the DM filter unit body 310 throughthe insert injection method.

The (3-4)th terminal 360 may include a (3-4)th body 361 disposedhorizontally, a (3-4)th frame 362 protruding downward from the (3-4)thbody 361, and a (3-4)th end portion 363 protruding horizontally from the(3-4)th body 361.

One region of the (3-4)th body 361 may be bent downward. For example,the (3-4)th frame 362, which is a bent end portion of one side of the(3-4)th terminal 360, may be formed by bending one side of the (3-4)thbody 361 downward. In addition, an end portion of the (3-4)th frame 362may be brought into contact with the controller cover 400 byhorizontally bending the end portion of the (3-4)th frame 362.Accordingly, the (3-4)th frame 362 may perform grounding.

The (3-4)th end portion 363 may be provided as one protrusion, asillustrated in FIG. 18 . Accordingly, as illustrated in FIG. 19 , the(3-4)th end portion 363 may be coupled to the (2-2)th protrusion 243 ofthe (2-2)th frame 242.

The DM filter 370 may be disposed between the (3-1)th terminal 330 andthe (3-2)th terminal 340.

The DM filter 370 may reduce a DM noise. For example, the (3-1)thterminal 330 and the (3-2)th terminal 340 may be used as power lines,and the DM filter 370 may reduce the CM noise, which is caused by a DMcurrent component, among conductive noises generated through the (3-1)thterminal 330 and the (3-2)th terminal 340 being used as the power lines.

A plurality of third wires 371 may be arranged in the DM filter 370, andthe third wires 371 may be electrically connected to each of the (3-1)thterminal 330 and the (3-2)th terminal 340.

The second capacitor 380 may be disposed above the DM filter unit body310. Here, a plurality of fourth wires 381 arranged in the secondcapacitor 380 may be electrically connected to each of the (3-2)thterminal 340 and the (3-3)th terminal 350.

FIG. 20 is a perspective view illustrating the controller cover of themotor assembly according to the embodiment, FIG. 21 is a bottomperspective view illustrating the controller cover of the motor assemblyaccording to the embodiment, FIG. 22 is a bottom view illustrating thecontroller cover of the motor assembly according to the embodiment, andFIG. 23 is an enlarged view of region A in FIG. 3 .

The controller cover 400 may be disposed on the opening of thecontroller housing 100. The controller cover 400 may be disposed betweenthe DM filter unit 300 and the substrate 600.

Referring to FIGS. 20 to 22 , the controller cover 400 may include acontroller cover body 410 disposed on the opening of the controllerhousing 100 and a third protruding part 420 protruding downward from thecontroller cover body 410. In addition, the controller cover 400 mayfurther include a sealing member 430 and an O-ring 440. Here, thecontroller cover body 410 may be referred to as a fourth body.

The controller cover body 410 and the third protruding part 420 may beintegrally formed. Accordingly, the controller cover 400 may be made ofa metal material. For example, the controller cover 400 may be made ofan aluminum material having good thermal conductivity through adie-casting method.

The controller cover body 410 may be formed in a plate shape.

The end portion of the (3-4)th frame 362 may be in contact with an uppersurface 411 of the controller cover body 410. Accordingly, thecontroller cover body 410 made of a metal material may performgrounding. Here, the third protruding part 420 may be in contact with amotor housing 10 of the motor 3.

A first groove 412 may be formed along an edge of the upper surface 411of the controller cover body 410. Here, the first groove 412 may beformed in a shape corresponding to the shape of the first protrudingpart 115 of the controller housing 100. Accordingly, the firstprotruding part 115 may be coupled to the first groove 412. Here, thefirst groove 412 may be referred to as a coupling groove.

Referring to FIG. 23 , two first grooves 412 may be formed. Accordingly,the coupling force and airtightness of the controller housing 100 andthe controller cover 400 may be improved.

The sealing member 430 may be further disposed in the first groove 412.As illustrated in FIG. 23 , the sealing member 430 is disposed betweenthe first protruding part 115 and the first groove 412 to furtherimprove the airtightness.

In addition, a plurality of fifth holes 413 are formed in the controllercover body 410. The fifth holes 413 may be formed to vertically passthrough the controller cover body 410. Thus, the frames of the firstconnector 700, the second connector 800, and the third terminal 320 andthe like may pass through the controller cover body 410 through thefifth holes 413. Here, the fifth hole 413 may be referred to as athrough hole.

A second groove 415 may be formed in a lower surface 414 of thecontroller cover body 410. Here, the second groove 415 may be referredto as a placement groove.

Further, a protrusion protruding downward may be further disposed on thelower surface of the controller cover body 410. In addition, theprotrusion may be integrally formed with the controller cover body 410.In addition, the protrusion may guide the placement of the power moduleunit 500.

The third protruding part 420 may be formed to protrude downward fromthe controller cover body 410. In addition, the third protruding part420 may be formed in a cylindrical shape.

The third protruding part 420 may be disposed inside the motor housing10 of the motor 3. Here, an outer circumferential surface of the thirdprotruding part 420 is in contact with an inner circumferential surfaceof the motor housing 10 to perform grounding. Here, the motor housing 10may be referred to as a second housing.

A third groove 421 may be formed along the outer circumferential surfaceof the third protruding part 420. The O-ring 440 may be disposed in thethird groove 421. Here, the third groove 421 may be referred to as anO-ring groove.

As illustrated in FIG. 23 , the O-ring 440 may improve airtightnessbetween the inner circumferential surface of the motor housing 10 andthe third protruding part 420.

FIG. 24 is a perspective view illustrating the power module unitaccording to the first embodiment of the motor assembly according to theembodiment, FIG. 25 is a bottom perspective view illustrating the powermodule unit according to the first embodiment of the motor assemblyaccording to the embodiment, FIG. 26 is an exploded perspective viewillustrating the power module unit according to the first embodiment ofthe motor assembly according to the embodiment, FIG. 27 is a plan viewillustrating the power module unit according to the first embodiment ofthe motor assembly according to the embodiment, FIG. 28 is a side viewillustrating the power module unit according to the first embodiment ofthe motor assembly according to the embodiment, FIG. 29 is a viewillustrating the power module of the power module unit according to thefirst embodiment, and FIG. 30 is a view illustrating a bracket of thepower module unit according to the first embodiment.

The power module unit 500 according to the first embodiment may transmita signal capable of controlling the motor 3. The power module unit 500may be disposed between the controller cover 400 and the substrate 600.

Referring to FIGS. 24 to 27 , the power module unit 500 may include apower module 510 and a bracket 520.

The power module 510 transmits a signal capable of controlling the motor3. Here, an automotive power module (APM) may be used as the powermodule 510. Accordingly, the power module 510 generates a great amountof heat than other components of the controller 2.

The power module 510 may include a power module body 511, a plurality offirst pins 512 protruding downward from one side of the power modulebody 511, and five terminal pins 513 disposed to protrude downward fromthe other side of the power module body 511. The power module 510 mayfurther include a fourth groove 514. Here, the power module body 511 maybe referred to as a fifth body.

As illustrated in FIG. 28 , the first pin 512 and the terminal pin 513may be spaced apart to face each other. In addition, an end portion ofthe first pin 512 is coupled to the substrate 600 to receive a signalfrom the substrate 600. Here, the first pin 512 may be fixed to thesubstrate 600 through soldering. Here, the first pin 512 may be referredto as a power module pin. In addition, the terminal pin 513 may bereferred to as a power module terminal.

Referring to FIG. 25 , the terminal pin 513 may include a first terminalpin 513 a and a second terminal pin 513 b.

Three first terminal pins 513 a may be electrically connected to fourthterminals 522 of the bracket 520. Accordingly, the power may be suppliedto the motor 3 through the fourth terminal 522. Here, the fourthterminal 522 may be referred to as a controller terminal.

Each of two second terminal pins 513 b is electrically connected to eachof the (3-2-1)th frame 342 a of the (3-2)th terminal 340 and the(3-3-3)th frame 352 c of the (3-3)th terminal 350 to receive the power.

When the power module 510 is disposed on the bracket 520, the fourthgroove 514, which is concavely formed, guides the assembly of the powermodule 510. Here, the fourth groove 514 may be referred to as a guidegroove.

As illustrated in FIG. 27 , two fourth grooves 514 may be formed at bothsides of the power module body 511. In addition, the fourth grooves 514may be disposed on a virtual line L passing through the power modulebody 511.

Meanwhile, the power module 510 may further include a third protrusion515. Here, the third protrusion 515 may be referred to as a couplingprotrusion.

Referring to FIG. 29 , the third protrusion 515 may be formed toprotrude downward from an end portion of the first terminal pin 513 a.For example, the third protrusion 515 may protrude in the same directionas a direction in which the first terminal pin 513 a protrudes. Here, anend portion of the third protrusion 515 may be coupled to the substrate600.

The end portion of the third protrusion 515 may be fixed to thesubstrate 600 through soldering. Accordingly, a sensor disposed on thesubstrate 600 may confirm whether a signal is transmitted to the motor 3through the third protrusion 515. In addition, the substrate 600 mayshut off the motor 3 by confirming the signal transmitted to the motor3.

As illustrated in FIG. 29 , a width W1 of the third protrusion 515 isless than a width W2 of the first terminal pin 513 a. Accordingly, thethird protrusion 515 may be easily disposed on and fixed to thesubstrate 600. Here, the width W1 of the third protrusion 515 determinesthe occupied space and soldering amount of the substrate 600.

The bracket 520 presses the power module 510 against the lower surface414 of the controller cover 400. Here, the coupling member 4 such as abolt may be used. Accordingly, heat generated in the power module 510 isconducted to the controller cover 400, and the conducted heat isdischarged to the outside through the motor housing 10 of the motor 3.That is, the heat dissipation effect of the controller 2 may beincreased due to the controller cover 400 made of a metal material.

The bracket 520 may include a bracket body 521 and the fourth terminal522. Here, the bracket body 521 may be made of a synthetic resinmaterial, and the fourth terminal 522 may be made of a metal material.Accordingly, the fourth terminal 522 may be disposed on the bracket body521 through an insert injection method. Here, the bracket body 521 maybe referred to as a sixth body.

The bracket body 521 may include a cavity 523 formed in the bracket body521, a fourth boss 524, a plate 525, hooks 526 disposed on the bracketbody 521 to be spaced apart from each other, a fourth protrusion 527,and a fourth protruding part 528. Here, the fourth boss 524, the plate525, the hook 526, the fourth protrusion 527, and the fourth protrudingpart 528 may be integrally formed with the bracket body 521. Here, thefourth boss 524 may be referred to as a bracket boss or boss part. Inaddition, the plate 525 may be referred to as a support part.

As illustrated in FIG. 26 , the power module body 511 of the powermodule 510 may be disposed in the cavity 523.

Three fourth bosses 524 may be formed to protrude downward from thebracket body 521. Each of the fourth bosses 524 may have a space formedtherein, and one side of the fourth terminal 522 may be disposed in thefourth boss 524.

In addition, each of the fourth bosses 524 guides the motor 3 to coupleto one region of a bus-bar terminal 62. Accordingly, one region of thebus-bar terminal 62 may be coupled to one side of the fourth terminal522 to receive one power of three-phase (U, V, and W) powers.

The plate 525 may be disposed below the bracket body 521 to cross thecavity 523, as illustrated in FIG. 25 . Here, the plate 525 may beformed in a plate shape. Accordingly, the plate 525 is in contact with alower surface 511 a of the power module body 511 so that the powermodule 510 is pressed against the controller cover 400.

The hooks 526 may be disposed on the bracket body 521 to be spaced apartfrom each other. Here, the hook 526 may be formed to protrude upwardfrom the bracket body 521.

When the power module 510 is disposed in the cavity 523, the hook 526fixes the power module body 511 to the bracket body 521. Here, since thesecond groove 415 may be formed in the lower surface 414 of thecontroller cover body 410, an end portion of the hook 526 may bedisposed in the second groove 415 of the controller cover 400.Accordingly, when the controller cover 400 is coupled to the powermodule unit 500, interference due to the hook 526 is prevented.

As illustrated in FIG. 27 , the hook 526 may be disposed to be spacedapart from the virtual line L passing through a center of the powermodule body 511 at a predetermined distance d. Accordingly, when thecontroller cover 400 is coupled to the power module unit 500, the powermodule unit 500 may be assembled at a preset position by the coupling ofthe second groove 415 and the hook 526.

As illustrated in FIG. 30 , the fourth protrusion 527 may be formed toprotrude toward an inner side of the cavity 523. In addition, the fourthprotrusion 527 is coupled to the fourth groove 514 of the power module510. Accordingly, when the power module 510 is coupled to the bracket520, the fourth protrusion 527 is disposed in the fourth groove 514 sothat the fourth protrusion 527 guides the coupling of the power module510. Here, the fourth protrusion 527 may be referred to as a guideprotrusion.

The fourth protruding part 528 may be formed to protrude downward fromthe bracket body 521. Here, the fourth protruding part 528 may bedisposed adjacent to the first pins 512. Here, the term “adjacent to”refers to being in contact with or disposed to be spaced apart atpredetermined intervals. Here, the fourth protruding part 528 may bereferred to as a protection part.

Thus, the fourth protruding part 528 may protect the first pin 512. Forexample, when the first pin 512 is coupled to the substrate 600, thefourth protruding part 528 supports one region of the first pin 512 toprevent or minimize the phenomenon in which the first pin 512 is bent.

As illustrated in FIG. 30 , the fourth protruding part 528 may include a(4-1)th protruding part 528 a and a plurality of (4-2)th protrudingparts 528 b.

The (4-1)th protruding part 528 a may be formed in a plate shape. And,the (4-2)th protruding parts 528 b may protrude toward the first pin 512from one surface of the (4-1)th protruding part 528 a. Accordingly, thefirst pin 512 may be disposed between the (4-2)th protruding parts 528b.

As illustrated in FIG. 28 , in order for the end portion of the firstpin 512 and the substrate 600 to be coupled to each other, a protrudingheight H1 of the fourth protruding part 528 is less than a protrudingheight H2 of the first pin 512 on the basis of the lower surface 414 ofthe controller cover 400. That is, the protruding height H2 of the firstpin 512 is greater than the protruding height H1 of the fourthprotruding part 528. Here, the protruding height may be referred to as aprotruding length.

The fourth terminal 522 electrically connects the first terminal pin 513a to the bus-bar terminal 62 of the motor 3.

Referring to FIGS. 25 and 27 , an end portion of one side of the fourthterminal 522 is bent downward and exposed, and an end portion of theother side thereof may be disposed inside the fourth boss 524.

FIG. 31 is a view illustrating the fourth terminal of the power moduleunit according to the first embodiment.

Referring to FIG. 31 , the fourth terminal 522 may include a fourth body522 a disposed horizontally, a fourth frame 522 b formed to protrudedownward from an end portion of one side of the fourth body 522 a, and afourth end portion 522 c bent downward from an end portion of the otherside of the fourth body 522 a and then bent in the horizontal direction.Here, a sixth hole 522 d may be formed in the fourth end portion 522 c.Here, the fourth end portion 522 c is disposed to be exposed inside thefourth boss 524. Here, the sixth hole 522 d may be referred to as aninsertion hole or hole.

The fourth frame 522 b may be disposed to be in contact with the firstterminal pin 513 a. Here, the contact force between the fourth frame 522b and the first terminal pin 513 a may be improved through a fusingprocess.

An end portion of the bus-bar terminal 62 may be coupled to the sixthhole 522 d. Here, two sixth holes 522 d may be formed to improve thecoupling force and contact force with the end portion of the bus-barterminal 62.

A heat transfer member (not shown) may be further disposed between thecontroller cover 400 and the power module 510 of the power module unit500. Accordingly, heat generated by the power module 510 is conducted tothe controller cover 400 through the heat transfer member. Here, athermal pad, a thermal grease, or the like may be used as the heattransfer member.

FIG. 32 is a view illustrating the substrate of the motor assemblyaccording to the embodiment.

The substrate 600 may prevent the reverse connection of the power. Here,the term “reverse connection” means that a positive polarity and anegative polarity of power sources are applied differently from thepreset polarities, and thus damage to the motor assembly 1 may occur dueto the reverse connection. Thus, even when the positive and negativepolarities of the power sources are applied differently from the presetpolarities, the substrate 600 may prevent damage due to the reverseconnection by using a metal-oxide-semiconductor field-effect transistor(MOSFET).

That is, the controller 2 receives power from the external connectorcoupled to the first boss 111, removes noises using the CM filter unit200 and the DM filter unit 300, and then transmits the power to thesubstrate 600. In addition, the power in which the reverse connection isprevented at the substrate 600 is transferred to the DM filter unit 300and then supplied to the power module unit 500 and the substrate 600.

In addition, the substrate 600 may transmit and receive signals to andfrom the external connector through the first connector 700 and thesecond connector 800. In addition, the substrate 600 may transmit andreceive signals to and from the power module unit 500.

Referring to FIG. 32 , the substrate 600 may include a substrate body610 on which circuit wiring is disposed, a plurality of seventh holes620, a MOSFET 630, and a sensor 640. Here, the substrate body 610 may bereferred to as a seventh body. In addition, the seventh holes 620 may bereferred to as through holes.

The plurality of seventh holes 620 may be formed in the substrate body610. In addition, the end portion of the third frame 322, the endportion of the (3-1)th frame 332, the end portion of the (3-2-2)th frame342 b, the end portion of the (3-3)th frame 352, the end portion of thefirst pin 512, the end portion of the third protrusion 515, and the likemay be disposed in the seventh holes 620. Further, each of the endportions may be soldered to be fixed to the substrate body 610.

The MOSFET 630 may be disposed on the substrate body 610.

The MOSFET 630 prevents the reverse connection of the power supplied tothe substrate body 610 after the noises are removed by the CM filterunit 200 and the DM filter unit 300.

The sensor 640 may be disposed on the substrate body 610.

The sensor 640 senses whether a signal is properly transmitted to themotor 3 through the third protrusion 515.

FIG. 33 is a view illustrating the first connector of the motor assemblyaccording to the embodiment.

The first connector 700 electrically connects the external connectorcoupled to the second boss 112 to the substrate 600. Here, one side ofthe first connector 700 is coupled to the substrate 600.

Referring to FIG. 33 , the first connector 700 may include a firstconnector body 710 and a plurality of first connector pins 720. Here,the first connector body 710 may be made of a synthetic resin material,and the first connector pin 720 may be made of a metal material. Inaddition, the first connector body 710 may be referred to as an eighthbody. Also, the first connector pin 720 may be referred to as a secondpin.

One side of the first connector pin 720 is connected to the externalconnector coupled to the second boss 112, and the other side of thefirst connector pin 720 is electrically connected to the substrate 600.

FIG. 34 is a view illustrating the second connector of the motorassembly according to the embodiment.

The second connector 800 electrically connects the external connectorcoupled to the third boss 113 to the substrate 600. Here, one side ofthe second connector 800 is coupled to the substrate 600.

Referring to FIG. 34 , the second connector 800 may include a secondconnector body 810 and a plurality of second connector pins 820. Here,the second connector body 810 may be made of a synthetic resin material,and the second connector pin 820 may be made of a metal material. Inaddition, the second connector body 810 may be referred to as a ninthbody. Further, the second connector pin 820 may be referred to as athird pin.

One side of the second connector pin 820 is connected to the externalconnector coupled to the third boss 113, and the other side of thesecond connector pin 820 is electrically connected to the substrate 600.

Referring to FIGS. 1 to 3 , the motor 3 according to the embodiment mayinclude the motor housing 10 having an opening formed at one sidethereof, a motor cover 20 covering the opening of the motor housing 10,a stator 30 disposed inside the housing 10, a rotor 40 rotatablydisposed in the stator 30, a rotation shaft 50 rotating together withthe rotor 40, and a bus bar 60. Here, a bearing 70 may be disposed on anouter circumferential surface of the rotation shaft 50 for the rotationof the rotation shaft 50. Here, the motor cover 20 may be referred to asa second cover part.

Here, the motor housing 10 and the motor cover 20 may form an outershape of the motor 3. In addition, an accommodation space may be formedby coupling the motor housing 10 to the motor cover 20. Accordingly, asillustrated in FIG. 3 , the stator 30, the rotor 40, the rotation shaft50, and the bus bar 60 may be disposed in the accommodation space.

The motor housing 10 may be formed in a cylindrical shape such that theaccommodation space is formed. The inner circumferential surface of themotor housing 10 may be coupled to the outer circumferential surface ofthe third protruding part 420

Here, the motor housing 10 may be made of a metal material. Accordingly,heat transmitted through the controller cover 400 is emitted to theoutside through the motor housing 10. In addition, the motor housing 10is in contact with the controller cover 400 and thus a groundingfunction may be performed.

The motor cover 20 is disposed in the opening of an upper side of themotor housing 10. Here, the bearing 70 may be disposed inside the motorcover 20.

The stator 30 may be disposed inside the motor housing 10. In addition,the stator 30 causes electrical interaction with the rotor 40.

Referring to FIG. 3 , the stator 30 may include a stator core 31 and acoil 33 wound around the stator core 31. In addition, the stator 30 mayfurther include an insulator 32 disposed between the stator core 31 andthe coil 33. The insulator 32 insulates the stator core 31 from the coil33.

The stator core 31 may be formed by stacking plates having a plate shapeat a predetermined height.

The rotor 40 may be disposed inside the stator 30 and may be disposed onthe outer circumferential surface of the rotation shaft 50. Here, therotor 40 may be rotatably disposed in the stator 30.

The rotor 40 may be formed by stacking a plurality of disk-shaped coreplates. Magnets disposed on the rotor 40 are disposed to face the stator30, and each of the magnets may be formed as an interior permanentmagnet (IPM) type that is inserted into and coupled to the rotor 40through a hole formed in the rotor 40.

The rotor 40 may be configured as a type in which a magnet is disposedon an outer circumferential surface of a rotor core.

Accordingly, the rotor 40 is rotated by the electric interaction betweenthe coil 33 and the magnet. In addition, the rotation shaft 50 rotatesas the rotor 40 rotates to generate a driving force.

The rotation shaft 50 may be disposed to pass through a central portionof the rotor 40. When a driving current is applied to the stator 30, therotor 40 is rotated by the electromagnetic interaction between thestator 30 and the rotor 40 so that the rotation shaft 50 rotates inconjunction with the rotation of the rotor 40.

The bus bar 60 is disposed above the stator 30.

The bus bar 60 may include a bus-bar body 61 and the bus-bar terminal 62disposed inside the bus-bar body 61. Here, the bus-bar body 61 may be amolded product formed through injection molding.

The bus-bar terminal 62 may be a phase terminal connected to powersources of a U-phase, a V-phase, or a W-phase.

Connecting end portions of the bus-bar terminal 62 are disposed to beexposed from the bus-bar body 61. Accordingly, the connecting endportion of the bus-bar terminal 62 may be connected to the coil 33 asillustrated in FIG. 3 .

FIG. 35 is a view illustrating the bus-bar terminal of the motorassembly according to the embodiment.

Referring to FIG. 35 , the bus-bar terminal 62 may include a bus-barterminal body 62 a and a fifth frame 62 b protruding upward from thebus-bar terminal body 62 a. Here, the fifth frame 62 b may be referredto as a coupling end portion.

The fifth frame 62 b may be disposed to protrude toward an upper side ofthe motor cover 20 through the motor cover 20.

An end portion of the fifth frame 62 b is guided by the fourth boss 524and coupled to one side of the fourth terminal 522 disposed inside thefourth boss 524. Here, two protrusions may be formed to be spaced apartfrom each other at the end portion of the fifth frame 62 b, and theprotrusions may be coupled to the sixth holes 522 d of the fourthterminal 522.

Meanwhile, a power module unit 500 a according to a second embodimentmay be disposed in the motor assembly 1 according to the embodimentinstead of the power module unit 500 according to the first embodiment.

FIG. 36 is an exploded perspective view illustrating the motor accordingto the embodiment in which the power module unit 500 a according to thesecond embodiment is disposed.

Referring to FIGS. 1 and 36 , the motor assembly 1 according to theembodiment may include the controller 2 and the motor 3. In addition,the controller 2 may include the controller housing 100, the CM filterunit 200, the DM filter unit 300, the controller cover 400, the powermodule unit 500 a according to the second embodiment, the substrate 600,the first connector 700, and the second connector 800.

Hereinafter, in describing the motor assembly 1 according to theembodiment in which the power module unit 500 a according to the secondembodiment is disposed, the same components described in the motorassembly 1, in which the power module unit 500 according to the firstembodiment is disposed, are described with the same reference numerals,and thus detailed descriptions of the controller housing 100, the CMfilter unit 200, the DM filter unit 300, the controller cover 400, thesubstrate 600, the first connector 700, and the second connector 800will be omitted.

Power in which the reverse connection is prevented at the substrate 600is transferred to the DM filter unit 300 and then supplied to the powermodule unit 500 a.

In addition, the power module unit 500 a transmits a signal capable ofcontrolling the motor 3. Here, the power module unit 500 a is pressedagainst the lower surface 414 of the controller cover 400.

FIG. 37 is a perspective view illustrating the power module unitaccording to the second embodiment of the motor assembly according tothe embodiment, FIG. 38 is a bottom perspective view illustrating thepower module unit according to the second embodiment of the motorassembly according to the embodiment, and FIG. 39 is a plan viewillustrating the power module unit according to the second embodiment ofthe motor assembly according to the embodiment.

Referring to FIGS. 37 to 39 , the power module unit 500 a may include apower module 510 a and a mold unit 530 surrounding the power module 510a. At this point, the power module 510 a may be disposed in the moldunit 530 through an injection method. Here, the mold unit 530 may bemade of a synthetic resin material. Since the power module unit 500 a isformed through the injection method, material costs and mold costs maybe reduced and thus production costs may be reduced.

The power module 510 a transmits a signal capable of controlling themotor 3. Here, an APM may be used as the power module 510 a.

FIG. 40 is a view illustrating the power module of the power module unitaccording to the second embodiment.

Referring to FIG. 40 , the power module 510 a may include a power modulebody 511 a, a plurality of power module pins 512 arranged to protrudedownward from one side of the power module body 511, and a terminalpart.

The terminal part may include two first power module terminals 513 beach having one region arranged to protrude downward from the other sideof the power module body 511 a and three second power module terminals516 each having one side connected to the power module body 511 a.

Here, the power module pin 512 is the same component as the first pin512 of the power module unit 500 according to the first embodiment.

In addition, the first power module terminal 513 b is the same componentas the second terminal pin 513 b of the power module unit 500 accordingto the first embodiment. In addition, the second power module terminal516 is a component obtained by modifying the first terminal pin 513 aand the fourth terminal 522 of the power module unit 500 according tothe first embodiment to be integrated.

One side of the power module body 511 a is disposed to be pressedagainst the lower surface 414 of the controller cover 400. Asillustrated in FIG. 37 , the power module body 511 a may be formed tohave a concave-convex shape in which a partial region thereof protrudes.That is, the power module body 511 a may include the power module body511 according to the first embodiment and a protruding region Aprotruding from one side of the power module body 511 according to thefirst embodiment.

Accordingly, when compared to the power module body 511 of the powermodule unit 500 according to the first embodiment, the power module body511 a has an increased contact area that is in contact with thecontroller cover 400 due to the protruding region A so that heatdissipation performance may be improved. In addition, since the size ofthe power module body 511 a may be increased, a degree of design freedommay be increased.

The power module pin 512 and the first power module terminal 513 b maybe disposed to be spaced apart from each other to face each other. Inaddition, an end portion of the power module pin 512 is coupled to thesubstrate 600 to receive a signal from the substrate 600. Here, thepower module pin 512 may be fixed to the substrate 600 throughsoldering.

One side of the first power module terminal 513 b is electricallyconnected to the power module body 511 a, and the other side thereof maybe bent downward.

As illustrated in FIG. 38 , one side of the first power module terminal513 b may be connected to the protruding region A of the power modulebody 511 a, and the other side of the first power module terminal 513 bmay protrude toward the outside of the mold unit 530. Here, the powermodule pin 512 and one region of the first power module terminal 513 bprotruding downward may be disposed to be spaced apart from each otherto face each other.

Each of two first power module terminals 513 b is electrically connectedto each of the (3-2-1)th frame 342 a of the (3-2)th terminal 340 and the(3-3-3)th frame 352 c of the (3-3)th terminal 350 to receive the power.Here, the first power module terminals 513 b may be disposed with theprotruding region A of the power module body 511 interposedtherebetween.

Power is supplied to the motor 3 through the second power moduleterminal 516. Here, the second power module terminal 516 may be made ofa metal material.

An end portion of one side of the second power module terminal 516 maybe connected to one side of the power module body 511 a, and an endportion of the other side of the second power module terminal 516 may bedisposed in a boss part 531. As illustrated in FIG. 40 , the end portionof one side of the second power module terminal 516 may be disposed inthe protruding region A of the power module body 511 a.

Referring to FIG. 40 , the second power module terminal 516 may includea fourth body 516 a that is horizontally disposed and has one side endportion connected to the protruding region A of the power module body511 a, and a fourth end portion 516 c that is bent downward from theother side end portion of the fourth body 516 a and then bent in ahorizontal direction. Here, a sixth hole 516 d may be formed at thefourth end portion 516 c. Here, the fourth end portion 516 c having thesixth hole 516 d formed therein is disposed to be exposed inside theboss part 531. Here, the fourth body 516 a may be referred to as a powermodule terminal body. In addition, the sixth hole 516 d may be referredto as an insertion hole or hole.

The end portion of the bus-bar terminal 62 may be coupled to the sixthhole 516 d. Here, two sixth holes 516 d may be formed to enhance thecoupling force and contact force with the end portion of the bus-barterminal 62.

The mold unit 530 may be disposed to surround one region of the powermodule 510 a. Here, the mold unit 530 may be divided into a first regionsurrounding the power module body 511 and a second region surroundingthe protruding region A.

The boss part 531 and a groove 532 may be formed in the mold unit 530.Here, the boss part 531 may be disposed in the second region. Inaddition, the groove 532 may be disposed in the first region.

Referring to FIG. 39 , a width W3 of one side of the mold unit 530 onwhich the boss part 531 is formed is less than a width W4 of the otherside of the mold unit 530 disposed to face the one side. For example,the width W3 of the second region is less than the width W4 of the firstregion. Here, width W3:width W4 is 16:37.

Each of three boss parts 531 may be formed to protrude downward from oneside of the mold unit 530. At this point, the boss part 531 protrudestoward the substrate 600 and is branched into three parts from the moldunit 530, as illustrated in FIG. 38 . Here, the boss part 531 may bedisposed in the second region to be adjacent to the protruding region A.

A space may be formed in each of the boss parts 531, and the fourth endportion 516 c of the second power module terminal 516 may be disposed inthe boss part 531. Here, the space may be formed to pass through from alower portion to an upper portion of the boss part 531.

In addition, each of the boss parts 531 guides the motor 3 to couple toone region of the bus-bar terminal 62. Accordingly, one region of thebus-bar terminal 62 may be coupled to the fourth end portion 516 c ofthe second power module terminal 516 to receive one power of three-phase(U, V, and W) powers.

Meanwhile, a protruding part 531 a may be further formed at a lower endof each of the boss parts 531.

The protruding part 531 a is formed to protrude downward from the lowerend of the boss part 531. Accordingly, the space of the boss part 531extends downward due to the protruding part 531 a. As illustrated inFIG. 38 , the protruding part 531 a may be formed in a quadrangularshape in a plan view.

Two grooves 532 may be formed at both sides of the power module body511. In addition, the power module unit 500 a is in close contact withand fixed to the lower surface 414 of the controller cover 400 by afastening member (not shown) such as a bolt or screw passing through thegroove 532.

Although the above-described descriptions are described with referenceto the embodiments of the present invention, it should be understoodthat those skilled in the art may be capable of variously modifying andchanging the present invention within the spirit and the scope disclosedin the claims which will be described below. In addition, it should beinterpreted that the differences related to the change and modificationfall within the range of the present invention defined by the appendedclaims.

Explanation of Reference Numerals

1: motor assembly, 10: motor housing, 20: motor cover, 60: bus bar, 100:controller housing, 200: common-mode (CM) filter unit, 300:differential-mode (DM) filter unit, 400: controller cover, 500 or 500 a:power module unit, 600: substrate, 630: metal-oxide-semiconductorfield-effect transistor (MOSFET), 700: first connector, 800: secondconnector.

1. A controller comprising: a first housing; a first cover disposed onan opening of the first housing; filter units disposed above the firstcover; a power module unit disposed below the first cover; and asubstrate disposed below the power module unit; wherein the power moduleunit includes: a bracket; and a power module disposed between thebracket and the first cover, wherein the power module includes: a powermodule body; a plurality of first pins arranged to protrude downwardfrom one side of the power module body; and five terminal pins arrangedto protrude downward from the other side of the power module body, andwherein an end portion of the first pin is coupled to the substrate. 2.The controller of claim 1, wherein a protrusion protrudes from an endportion of each of three terminal pins among the terminal pins, andwherein an end portion of the protrusion is coupled to the substrate. 3.The controller of claim 2, wherein one surface of the power module ispressed against the first cover, which is made of a metal material, bythe bracket.
 4. The controller of claim 2, wherein the bracket includes:a bracket body having a structure of a cavity in which the power moduleis disposed and three bosses protrude downward; and a terminal havingone side disposed to be exposed inside each of the bosses and the otherside disposed on the bracket body to protrude downward.
 5. Thecontroller of claim 4, wherein the terminal is in contact with theterminal pin on which the protrusion is formed.
 6. The controller ofclaim 5, wherein the bracket further includes a plate disposed below thebracket body to traverse the cavity.
 7. The controller of claim 6,wherein the bracket further includes at least two hooks protruding fromthe bracket body, and the power module may be fixed to the bracket bythe hooks.
 8. The controller of claim 7, wherein the hooks are disposedto be spaced apart from each other at predetermined intervals withrespect to a virtual line L passing through a center of the powermodule.
 9. The controller of claim 8, wherein a groove is formed on alower surface of the first cover such that an end portion of the hooksis disposed therein.
 10. The controller of claim 9, wherein the bracketfurther includes a protruding part protruding downward from the bracketbody, and the protruding part may be disposed to be adjacent to thefirst pin.
 11. The controller of claim 10, wherein a protruding heightof the first pin may be greater than a protruding height of theprotruding part.
 12. The controller of claim 10, wherein the terminalincludes: a body disposed horizontally, a frame formed to protrudedownward from an end portion of one side of the body, and an end portionbent at an end portion of the other side of the body and disposed insidethe boss, and wherein the frame is in contact with the terminal pin. 13.The controller of claim 12, wherein a hole is formed in the end portion.14. The controller of claim 1, further comprising: a heat transfermember disposed between the power module body and the first cover. 15.The controller of claim 2, wherein a width of the protrusion is lessthan the width of the terminal pin.
 16. A motor assembly comprising: amotor controller; and a motor, wherein the motor controller includes: afirst housing; a first cover disposed on an opening of the firsthousing; filter units disposed above the first cover; a power moduleunit disposed below the first cover; and a substrate disposed below thepower module unit, wherein the power module unit includes: a bracket;and a power module disposed between the bracket and the first cover,wherein the power module includes: a power module body; a plurality offirst pins arranged to protrude downward from one side of the powermodule body; five terminal pins arranged to protrude downward from theother side of the power module body; and a protrusion protruding from anend portion of each of three terminal pins among the terminal pins, andwherein an end portion of the protrusion is coupled to the substrate.17. The motor assembly of claim 16, wherein a width of the protrusion isless than the width of the terminal pin.
 18. The motor assembly of claim16, wherein one surface of the power module is pressed against the firstcover, which is made of a metal material, by the bracket.
 19. The motorassembly of claim 16, wherein the motor includes a rotation shaft, arotor disposed outside the rotation shaft, a stator disposed outside therotor, a bus bar disposed above the stator, a second housingaccommodating the rotor, the stator, and the bus bar, and a second coverdisposed on an opening of the second housing, wherein the bus barincludes a bus-bar body and a bus-bar terminal, wherein the bracketincludes: a bracket body having a structure of a cavity in which thepower module is disposed and three bosses protrude downward; and aterminal having one side disposed to be exposed inside each of thebosses and the other side disposed on the bracket body to protrudedownward, and wherein one side of the bus-bar terminal is coupled to ahole of the terminal.
 20. The motor assembly of claim 16, wherein theterminal is in contact with the terminal pin on which the protrusion isformed.